Shock absorbing floor covering system

ABSTRACT

The present invention provides a cushioned impervious flooring usually formed in place. At least one layer of closed cell cushion is overlaid with a reinforcing mesh having interstitial spaces, a layer of adhesive is applied to adhere the reinforcing mesh to the cushion and to adhere the reinforcing layer to a layer of sheet flooring. Tapered edges provide gentle transition from the cushioned impervious flooring to adjacent surfaces at a different elevation. Joints in the closed cell cushion, reinforcing layer and sheet flooring are offset from each other to provide smooth installation and more strength.

CROSS REFERENCE TO A RELATED APPLICATION

None

FEDERALLY SPONSORED RESEARCH

None

FIELD OF THE INVENTION

This invention relates to flooring that is impervious to liquids and provides a cushioned surface to reduce the impact force while walking on the flooring and to provide cushioning in case of a person or an object person falling on the floor.

1. Background of the Invention

This invention relates to floor coverings with surfaces impervious to liquids, and which possess cushioning properties to reduce the shock of impact, for example, in case a person should fall on the surface. This invention relates to an impervious flat layer to be used as a floor surface, and the layer can be sheet flooring, sheet vinyl, polypropylene sheet, polyethylene sheet, sheet, nylon sheet, or any other hard surface to allow for easy clean up, mopping, wiping, or similar cleaning method. This is the top layer that provides the impermeable barrier to the shock absorbing floor system. A layer of reinforcing mesh resists puncture and pressure stress, as for example a small shoe heel.

2. Description of Related Art

This art is related, but different, from cushioned floor coverings which are covered with carpet, both for indoor and outdoor use. Such systems are described in my U.S. Pat. Nos. 6,090,462 and 6,572,952 on Shock Absorbing Carpet Systems. Cushioned carpet floor coverings can absorb liquids, as described in my patents. The usual impervious floor coverings such as sheet flooring are applied over concrete, plywood or similar hard surfaces which have no shock absorbing properties.

SUMMARY OF THE INVENTION

A liquid impermeable shock absorbing floor covering comprising a closed cell cushion; a reinforcing mesh atop the closed cell cushion, the reinforcing material having interstitial spaces which may be in the form of perforations; the perforations forming multiple strands in a first direction and multiple strands angular to said first direction between said perforations; a layer of adhesive applied atop the reinforcing material and through the perforations to adhere the reinforcing mesh to the cushion; and a layer of sheet flooring applied with decorative side up, and an opposite side down, atop the layer of adhesive to adhere the sheet flooring to the reinforcing material and cushion. A tapered edge eases approach and departure from the cushioned flooring where there is a difference in the elevation of the adjacent surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross section view of the invention.

FIG. 2 is an exploded cross section of the invention as shown in FIG. 1.

FIG. 3 is an alternate embodiment of the invention on an area large enough to require multiple widths of closed cell cushions.

FIG. 4 is another alternate embodiment of the invention.

FIG. 5 is a plan view of another alternate embodiment of the invention.

FIG. 6 is a plan view of the reinforcing mesh used in the preferred embodiment.

FIG. 7 is a plan view showing an arrangement of the components of the alternate embodiment of FIG. 4

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of this invention, sheet flooring, commonly understood words, which is used herein to describe any number of sheet materials which are impervious to liquids, for example, sheet vinyl. For the purposes of this invention, reinforcing mesh refers to a sheet material having interstitial spaces which may be perforations as described below, or a sheet material having random passages communicating through the sheet material, a material woven of plastic or a metal, as for example steel or aluminum.

Referring to FIG. 1, There is a closed cell rubber cushion 12, there is a cross section of my invention shown generally at 1. Cushions are generally available in ¼, ⅜, ½, ⅝, ¾, ⅞ or 1 inch thicknesses, depending on the application, the need to bring a floor to a desired elevation, or the amount of cushioning desired. Greater cushion thickness, for example 1¼, 1″½ inches, or even thicker may be utilized to achieve the desired energy absorption properties desired. Two cushions of any given thicknesses may be utilized to build up sufficient thickness to achieve the desired cushioning effect. For example, the 1½ inch thickness may be achieved by using 1 inch and ½ inch thickness cushions, or two ¾ inch layers of cushions 12 and 18 may be utilized.

A reinforcing mesh 14 with interstitial spaces 20 is used as a reinforcing; layer in my preferred embodiment. Perforations 20, see FIG. 6, in the reinforcing mesh allow the reinforcing mesh 14 to be placed atop the cushion 12 for assembly of the shock absorbing floor covering system so that adhesive 10 (not shown) may then be applied to the top of the reinforcing mesh 14 and the adhesive 10 (not shown) flows through the perforations 20 to adhere the reinforcing mesh 14 to the closed cell rubber cushion 12. Sufficient adhesive 10 is applied so that sheet flooring 16 may be applied atop the reinforcing mesh 14 and adhered to the reinforcing mesh 14 and the closed cell rubber cushion 12. Sheet flooring 16 may be decorative by having a pattern or one or more solid colors. Interstitial spaces impart a permeable property the reinforcing mesh 14 so that adhesive applied to the top of the mesh 14 will permeate the mesh 14 and come in contact with the closed cell rubber cushion 12.

The reinforcing mesh 14 also provides an important reinforcement property to my shock absorbing floor covering system. The reinforcing mesh 14 provides strength below the sheet flooring to withstand the stress of small area heels which are a feature of many ladies' dress shoes. I have measured the heels on some ladies shoes. Some are as small as ⅜ (0.375) inches wide by ½ (0.500) inches long with a 3/16 (0.1874) inch radius on the back of the heel. This represents an area of 0.1724 square inches with a perimeter of 1.5890 inches. If a person weighing 130 pounds should impose this entire weight in a heel, the pressure would be 130 divided by 0.1724 square inches, or 754 pounds per square inch pressure. The shear stress on the sheet flooring would be 130 divided by the perimeter, 1.589 inches, or 81.8 pounds per inch shear stress in the floor. Such situations impose such stresses on a cushioned sheet floor that sheet flooring 16 on a closed cell cushion 12 could lead to shear or pressure failure of the sheet flooring 16. In the present invention, I use polyethylene reinforcing mesh 14 made of a single sheet of polyethylene with at least 5 strands per inch measured between closest adjacent perforations in one direction and at least 5 strands per inch measured between closest adjacent perforations measured angularly to the one direction. In this way, the strands are close enough together to support concentrated loads such as a small heel In any case, in order to have the strands close enough together to support concentrated loads such as a small heel, there should be, in effect, at least 3 strands per inch, measured between closest adjacent perforations. Strands are referred to as the connective material in a single uniform sheet of the plastic. For the purposes of this invention a permeable material without finite perforations is equivalent to the reinforcing mesh 14 described herein.

FIG. 2 is an exploded cross section view of my invention illustrating the closed cell rubber cushion 12, the reinforcing mesh 14 and sheet flooring 16 as they are applied to a floor to achieve a cushioned, impervious floor with the reinforcing mesh which provides strength to small areas of stress, yet allows the closed cell rubber cushion 12 to provide energy absorption for added safety in case a person should fall.

FIG. 3 illustrates the arrangement and method of applying the invention to a floor larger than the available widths of cushion, reinforcing mesh or sheet flooring. In such case, the pieces of closed cell cushion 12 are laid down to cover the area, and abut at joint 13. Then the pieces of reinforcing mesh 14 are laid down so that the abutting joints 15 are offset from joints in the closed cell cushion 12. Then the adhesive 10 (not shown) is applied and the sheet flooring 16 is laid down so that the abutting joints 17 are offset from joints 15 in the reinforcing mesh and the joints 13 in the closed cell cushion 12. Where an area is larger than can be covered with a single width of sheet flooring 16, abutting joints 17 are sealed with the best available method for sealing liquid impermeable joints 17. Commercially available contact cement should be used for the joints 13 and 19 between closed cell cushions 12 and between closed cell cushions 18.

FIG. 4 illustrates an alternate embodiment of the invention. In case there is a need for a greater thickness of closed cell rubber cushion, which some manufacturers provide in thicknesses up to 1 inch, I use multiple layers of the closed cell rubber cushion. For example, a 1.5 inch thickness is conveniently achieved by use of a ½ inch thick cushion, and a 1 inch cushion. The thicker material may be placed first, although there is more stability with the thicker cushion atop the thinner cushion. Also, a 1.5 inch thickness is conveniently achieved by use of two ¾ inch thick cushions. As described in FIG. 3, pieces of closed cell cushion 18 are laid down to cover the area, and abut at joint 19. Then a commercially available spray adhesive is sprayed on top of, and along each side of joints 19 to provide stability between the layers of cushion 18 and cushion 12. Pieces of closed cell cushion 12 are laid down to cover the area, and abut at joint 13. Then the pieces of reinforcing mesh 14 are laid down so that the abutting joints 15 are offset from joints 13 in the closed cell cushion 12 and from joints 19 in cushion 18. Then the adhesive 10 is applied on and through reinforcing mesh 14 into contact with cushion 12, and the sheet flooring 16 is laid down so that the abutting joints 17 are offset from joints 15 in the mesh 14 and the joints 13 in the closed cell cushion 12.

In the preferred embodiment, I use a commercially available floor adhesive 10. I use closed cell foam for cushions 12 and 18. I use polyethylene reinforcing mesh for reinforcing mesh 14. A number of impermeable sheet coverings may be used as the sheet flooring 16, such as Forbo Marmoleum® or Armstrong Linoleum®, or other impermeable sheet materials from other manufacturers. High grade sheet vinyl such as Toli and Forbo sheet vinyl can also be used in the system

FIG. 5 illustrates a tapered edge where there is a difference between the cushioned flooring and adjacent flooring. The dimensions T and W appear, showing the thickness T and width W of the mat. I now find that the width W of the taper may need to vary from 1 up to 24 times the thickness T of the flooring so that the ratio of W to T may vary from 1 to 24. Ratios between 6 and 18 are quite usable. A ratio of 1 to 12 provides a gentle slope so that a person in a wheelchair or using a walker or who may be walking unsteadily without one of these aids will find the slope provides a reasonable transition to and from the cushioned flooring.

FIG. 6 is a plan view of the reinforcing mesh 14. This reinforcing mesh has perforations 20 spaced at least 5 per inch in one direction and at least 5 per inch in an angular direction and provides support for concentrated loads on the sheet flooring 16, yet allows flexibility in the sheet flooring 16 and cushion 12 to absorb energy of a possible fall of a person or object.

FIG. 7 Illustrates a plan view with hidden lines showing offset joints of abutting cushions, reinforcing mesh and sheet flooring. Preferably, the edges 13,15,17, and 19, respectively of the of the cushion 12, reinforcing mesh 14 and sheet flooring 16 and bottom layer of cushion 18, are offset from alignment, one above the other. The cushioned flooring system of this invention is usually formed in place on site where it is to be utilized. Therefore, it is convenient to offset the joints 13, 15, 17 and 19 from each other, since the respective joints can be seen when preparing a piece of the next layer to be positioned on the floor.

This invention provides a layer of reinforcing material 14 under the sheet flooring 16 to support pressure and shear loads that would otherwise cause damage to the sheet flooring 16 when it is subjected to high stresses caused by for example, small heels on shoes, and from other sources, such as falling objects. This invention also provides an efficient assembly method, by the use of a perforated reinforcing layer 14. The perforations 20 make up a small enough percentage of the area of the reinforcing layer 14, yet are spaced so that the reinforcing layer 14 may be placed on top of the cushion 12, and a single coating of adhesive 10 can be applied, for example, with a roller or a trowel. The perforations 20 in the reinforcing layer allow the adhesive 10 to pass through the reinforcing layer 14 into contact with the cushion 12. The sheet flooring is then applied onto the adhesive 10 on the reinforcing layer. The adhesive 10 thus applied will adhere the sheet flooring 16 to the reinforcing layer 14 and also pass through the reinforcing layer 14 to the cushion 12, effectively achieving a bond between all three top layers of the flooring system with one application of adhesive 10. This shock absorbing floor covering may be manufactured in standard or custom sizes and taken to a site and placed in service. Preferably, for larger area, the shock absorbing floor is laid in place with the cushion pieces 12 and perforated reinforcing layer 14 cut to fit the desired area Then a layer of adhesive 10 is applied to the reinforcing layer 14 so as to flow through the reinforcing layer 14 into contact with the cushion. Then the sheet flooring 16 which has been cut to size is laid in contact with the adhesive 10 and reinforcing layer 14. Edges of adjacent pieces of the sheet material 16 may be joined into a sealing relationship to form a continuous liquid proof cushioned surface. A spray adhesive or contact cement may be used to join the edges.

I have found that the method of making an impermeable cushioned floor covering 1, comprising the steps of placing a closed cell cushion 12; placing a permeable reinforcing layer 14 on top of the closed cell cushion 12; applying an adhesive 10 on the reinforcing layer 14 and through the permeable reinforcing layer 14 into contact with the closed cell cushion 12; and placing an impermeable sheet 16 on the reinforcing layer 14 and in contact with the adhesive 10 is an efficient and effective of constructing a floor according to my invention. The permeable reinforcing layer 14 may be perforated plastic sheet, a permeable sheet without discrete perforations, or a woven metal reinforcing mesh. In the preferred usage, metal mesh should have a minimum of at least 5 strands per inch measured between closest adjacent strands in one direction and at least 5 strands per inch measured between closest adjacent perforations measured angularly to the one direction. In this way, the strands are close enough together to support concentrated loads such as a small heel. In any case, in order to have the strands close enough together to support concentrated loads such as a small heel, there should be, in effect, at least 3 strands per inch, measured between closest adjacent perforations in the metal mesh. The adhesive is placed within a plurality of the perforations, and the adhesive adheres the cushion directly to the underside of the sheet flooring within the perforations.

The reinforcing mesh 14 in my invention must be permeable to the adhesive 10, so as to practice my preferred method of construction. In my preferred method, the flooring 1 is constructed according to the method described in the preceding paragraph. The reinforcing mesh has interstitial spaces and therefore is permeable, that is, having pores or openings that permit the adhesive 10 to pass through the reinforcing mesh 14 to adhere the reinforcing mesh 14 to the cushion 12, as well as adhere the reinforcing mesh to the sheet flooring 16. The reinforcing mesh may be a plastic reinforcing mesh formed with an array of holes to provide for flow of adhesive 10. The reinforcing mesh may also be a woven metal reinforcing mesh, such as a metal screen such as that used for a screen window. Or it may be metal mesh commonly referred to as hardware cloth. The metal may be steel, aluminum, or other suitable metal, and may be perforated sheet material, or may be woven from wire. 

1. A shock absorbing floor covering comprising: a layer of closed cell cushion; a layer of reinforcing mesh having a plurality of interstitial spaces there through; a layer of sheet flooring having a decorative side and an opposite underside; a layer of adhesive substantially coating said reinforcing mesh and said interstitial spaces, said adhesive adhering said underside of said sheet flooring to said reinforcing mesh and said cushion.
 2. A shock absorbing floor covering comprising: a layer of closed cell cushion; a layer of reinforcing material comprising; a plurality of first strands oriented in a first direction; a plurality of second strands oriented in angular relation to said first strands; and, a plurality of perforations formed between said first and second strands; a layer of sheet flooring having a decorative side and an opposite underside; a layer of adhesive substantially coating said reinforcing layer and said perforations, said adhesive adhering said underside of said sheet flooring to said reinforcing material, and said reinforcing material to said cushion.
 3. The shock absorbing floor covering according to claim 1, further comprising: said adhesive being located within a plurality of said interstitial spaces, and said adhesive adhering said cushion directly to said underside of said sheet flooring within said interstitial spaces.
 4. The shock absorbing floor covering according to claim 1, further comprising: said closed cell cushion provided in sections having cushion edges; said reinforcing layer provided in sections having reinforcing edges; said sheet flooring provided in sections having flooring edges; and, said cushion edges, said reinforcing edges, and said flooring edges are substantially offset from each other.
 5. The shock absorbing floor covering according to claim 1, further comprising: said closed cell cushion having a tapered edge.
 6. The shock absorbing floor covering according to claim 1 wherein said closed cell cushion is at least 0.25 inches thick.
 7. The shock absorbing floor covering according to claim 1 wherein said closed cell cushion is at least 0.50 inch thick
 8. The shock absorbing floor covering according to claim 1 wherein said closed cell cushion is at least 1.0 inches thick
 9. The shock absorbing floor covering according to claim 1 wherein said at least one layer of closed cell cushion closed cell cushion is at least two layers and is at least 1.0 inches thick
 10. The shock absorbing floor covering according to claim 2 wherein said layer of reinforcing material atop said closed cell cushion, said reinforcing material has at least 3 strands per inch in a first direction and at least 3 strands angularly to said first direction
 11. The shock absorbing floor covering according to claim 2 wherein said layer of reinforcing material atop said closed cell cushion, said reinforcing material has at least 5 strands per inch in a first direction and at least 5 strands angularly to said first direction
 12. A shock absorbing floor covering comprising: a closed cell cushion having a thickness and a tapered edge; a layer of reinforcing material atop said closed cell cushion, said reinforcing material having multiple perforations; a layer of adhesive applied atop said reinforcing material and through said perforations to adhere said layer of reinforcing material to said cushion of sheet flooring; a layer of sheet flooring applied with decorative side up atop said layer of adhesive to adhere said sheet flooring to said reinforcing material and cushion.
 13. The shock absorbing floor covering of claim 12 wherein said tapered edge is between 1 and 24 times as wide as said thickness of said closed cell cushion.
 14. The shock absorbing floor covering of claim 12 wherein said tapered edge is between 6 and 18 times as wide as said thickness of said closed cell cushion.
 15. The shock absorbing floor covering of claim 12 wherein said tapered edge is substantially 12 times as wide as said thickness of said closed cell cushion.
 16. A shock absorbing floor covering comprising: a closed cell cushion having a tapered edge; a layer of perforated reinforcing material atop said closed cell cushion; a layer of adhesive applied to said reinforcing material and through said perforations to adhere said layer of perforated reinforcing material to said closed cell cushion; and a layer of sheet flooring applied with decorative side up atop said layer of adhesive to adhere said sheet flooring to said reinforcing material and cushion.
 17. The method of making an impermeable cushioned floor covering comprising said steps of: placing a closed cell cushion; placing a permeable reinforcing layer on top of said closed cell cushion; applying an adhesive on said reinforcing layer and through said permeable reinforcing layer into contact with said closed cell cushion; and placing an impermeable sheet on said reinforcing layer and in contact with said adhesive.
 18. The method of making an impermeable cushioned floor covering of claim 17 wherein said permeable reinforcing layer is perforated plastic sheet.
 19. The method of making an impermeable cushioned floor covering of claim 17 wherein said permeable reinforcing layer is a woven metal mesh.
 20. The method of making an impermeable cushioned floor covering of claim 17 wherein said impermeable reinforcing layer is plastic sheet.
 21. The method of making an impermeable cushioned floor covering of claim 17 wherein said impermeable reinforcing layer is sheet flooring.
 22. The method of making an impermeable cushioned floor covering of claim 17 wherein said permeable reinforcing layer is a woven steel mesh.
 23. The method of making an impermeable cushioned floor covering of claim 17 wherein said permeable reinforcing layer is a woven aluminum mesh. 